Communications cables incorporating separator structures

• US 10,121,571 B1
• Filed: 08/31/2016
• Issued: 11/06/2018
• Est. Priority Date: 08/31/2016
• Status: Active Grant

• Current Assignee: Superior Essex International IP
• Original Assignee: Superior Essex International Lp (LS Corporation)
• Inventors: McNutt, Christopher W., Sekhavat, Amir
• Primary Examiner(s): Mayo, III, William H
• Assistant Examiner(s): Robinson, Krystal
• Application Number:
  US15/252,775
• Time in Patent Office: 797 Days
• Field of Search: 174660, 174 72 A, 174113 R, 701102
• CPC Class Codes: H01B 11/06 with means for reducing effects of electromagnetic or electrostatic disturbances, e.g. screens
• CPC Class Codes: H01B 7/0216 Two layers

Abstract

A cable may include a plurality of longitudinally extending twisted pairs of individually insulated conductors. A longitudinally extending separator may be positioned between the plurality of twisted pairs. The separator may include at least one portion that extends beyond and is wrapped at least partially around an outer periphery of the plurality of twisted pairs. The at least one extending portion may have a variable thickness or one or more ribs may be formed on a surface of the extending portion. Additionally, a jacket may be formed around the plurality of twisted pairs and the separator.

Claims

1. A cable comprising:

a plurality of longitudinally extending twisted pairs of individually insulated electrical conductors;

a longitudinally extending separator positioned between the plurality of twisted pairs and comprising at least one portion that extends beyond and is wrapped at least partially around an outer periphery of the plurality of twisted pairs such that the at least one extending portion contacts another portion of the separator, wherein a plurality of ribs are formed only on the at least one extending portion of the separator; and

a jacket formed around the plurality of twisted pairs and the separator.

2. The cable of claim 1, wherein the plurality of ribs extend in a common direction from a surface of the at least one extending portion.

3. The cable of claim 1, wherein the plurality of ribs comprise at least one of (i) a plurality of longitudinally extending ribs, (ii) a plurality of ribs formed at an angle with respect to a longitudinal direction, or (iii) a plurality of ribs spaced along a longitudinal direction.

4. The cable of claim 2, wherein the plurality of ribs extend from the surface towards the jacket.

5. The cable of claim 1, wherein at least one of the plurality of ribs has one of (i) an approximately rectangular cross-sectional shape, (ii) an approximately convex cross-sectional shape, (iii) an approximately triangular cross-sectional shape, or (iv) an approximately trapezoidal cross-sectional shape.

6. The cable of claim 1, wherein the separator comprises a plurality of extending portions that are each wrapped at least partially around the outer periphery of the plurality of twisted pairs.

7. The cable of claim 1, wherein the separator is formed from one of (i) an extruded polymeric material or (ii) a foamed polymeric material.

8. The cable of claim 1, wherein the separator comprises a central portion and the at least one extending portion extends from the central portion, and wherein the central portion comprises one of (i) an approximately cross-shaped cross-section, (ii) an approximately flat cross-section, or (ii) approximately T-shaped cross-section.

9. The cable of claim 1, further comprising shielding material incorporated into the separator.

10. A cable comprising:

a jacket defining a longitudinally extending cavity;

a plurality of longitudinally extending twisted pairs of individually insulated electrical conductors positioned within the cavity; and

a longitudinally extending separator positioned between the plurality of twisted pairs and comprising a plurality of projections, each projection comprising;

a first portion positioned between a respective adjacent set of the plurality of twisted pairs and extending to an outer periphery defined by the adjacent set of the twisted pairs; and

a second portion that extends from the first portion beyond the outer periphery of the plurality of twisted pairs and that forms at least a partial outer wrap around the plurality of twisted pairs,

wherein each of the second portions comprises a respective plurality of ribs extending in a common direction from a surface of the extending portion, each of the plurality of ribs having a maximum thickness corresponding to a desired separation distance between the jacket and the plurality of twisted pairs, and

wherein each of the second portions is wrapped in a single and common direction around the outer periphery of the plurality of twisted pairs.

11. The cable of claim 10, wherein the respective plurality of ribs extend from the one or more extending portions towards the jacket.

12. The cable of claim 10, wherein at least one of the plurality of ribs has one of (i) an approximately rectangular cross-sectional shape, (ii) an approximately convex cross-sectional shape, (iii) an approximately triangular cross-sectional shape, or (iv) an approximately trapezoidal cross-sectional shape.

13. The cable of claim 10, wherein the separator is formed from one of (i) an extruded polymeric material or (ii) a foamed polymeric material.

14. The cable of claim 10, wherein the plurality of projections of the separator comprise one of (i) an approximately cross-shaped cross-section, (ii) an approximately flat cross-section, or (ii) approximately T-shaped cross-section.

15. The cable of claim 10, further comprising shielding material incorporated into the separator.

16. A cable comprising:

a plurality of longitudinally extending twisted pairs of individually insulated electrical conductors;

a longitudinally extending separator comprising;

a central portion positioned between the plurality of twisted pairs and extending between one or more adjacent sets of the plurality of twisted pairs to an outer periphery defined by the plurality of twisted pairs; and

a plurality of extending portions that extend from the central portion beyond an outer periphery of the of twisted pairs, wherein the plurality of extending portions are wrapped around the outer periphery in a single and common direction, each of the extending portions comprising a respective plurality of thickness variations, wherein each of the plurality of extending portions contacts another portion of the separator when wrapped around the outer periphery; and

a jacket formed around the plurality of twisted pairs and the separator.

17. The cable of claim 16, wherein at least one of the thickness variations has a maximum thickness that corresponds to a desired separation distance between the jacket and the plurality of twisted pairs.

18. The cable of claim 16, wherein at least one of the plurality of extending portions comprises a plurality of ribs extending from a surface of the at least one extending portion.

19. The cable of claim 16, wherein the separator is formed from one of (i) an extruded polymeric material or (ii) a foamed polymeric material.

20. The cable of claim 16, further comprising shielding material incorporated into the separator.